Optimization of an aircraft bracket by topology, production and analysis with selective laser melting method

In this study, the application of topology optimization in Ansys 2019 R1 software for a bearing bracket used in the aircraft warehouse door system and its production with additive manufacturing technologies are discussed. Considering the Safety Factor value, topology optimization was made for the bearing bracket for three different materials (Ti6Al4V, 316L Stainless Steel and Maraging Steel). Arrangements and analyzes were made on the geometry obtained as a result of the optimization. Maraging Steel with a safety factor value of 0.57058 was determined as the safest material that provides the highest performance. As a result of the optimization, the original bracket weight was reduced by 58.55%. Prototypes were produced to anticipate the difficulties to be encountered in production with SLE. Creality Ender 3 Pro device with FDM (Fused Deposition Modeling) technology was used in prototype production. ST-PLA 1.75 mm White was used as the printing material. Its suitability for prototype production and additive manufacturing has been tested and approved, and it has been produced using the Selective Laser Melting (SLE) method with Maraging Steel.